Sensing exposure to environmental factors

ABSTRACT

A method of sensing exposure to one or more of a plurality of environmental factors includes exposing a code circuit to at least some of the environmental factors, the code circuit disposed over a substrate and including a plurality of electrically-connected sensor patches, each sensor patch susceptible to one of the environmental factors, wherein the code circuit has an electrical state. An electrical excitation signal is passed through the code circuit, and a corresponding received electrical signal detected, using a transceiver formed on a transceiver substrate separate from and disposed over the substrate, wherein the transceiver includes a controller and the received electrical signal depends on the excitation signal and the electrical state of the code circuit. Using the controller, the received electrical signal or a representation thereof is automatically stored in a memory. The checking and storing steps are automatically repeated after one or more selected time intervals.

CROSS REFERENCE TO RELATED APPLICATIONS

Reference is made to U.S. application Ser. No. 13/600,258, co-filedherewith, titled “ELECTRONIC SENSING SYSTEM WITH ENVIRONMENTAL SENSORPATCH;” U.S. application Ser. No. 13/600,338, co-filed herewith, titled“ELECTRONIC SENSING SYSTEM WITH ENVIRONMENTAL SENSOR PATCHES;” and U.S.application Ser. No. 13/455,402, filed Apr. 25, 2012, titled “MAKINGSTORAGE SYSTEM HAVING MODIFIABLE CONDUCTOR AND MEMORY;” the disclosuresof which are incorporated by reference herein in their entirety.

FIELD OF THE INVENTION

The present invention relates to sensing environmental factors,particularly to monitoring exposure to environmental factors over time.

BACKGROUND OF THE INVENTION

Radio-frequency identification (RFID) is an established technology forcommunicating with small electronic devices (“tags”) that can beattached to pallets, packages, or product instances. RFID tags caninclude passive circuits in an integrated circuit (IC) that respond to aradio signal with stored identification or other data. The radio signalis provided by a “reader” (or “interrogator”) that commands the tag totransmit its stored data. U.S. Patent Publication No. 2008/0204238describes a variety of RFID-enabled devices. In this publication, theterm “reader” refers to any electronic device capable of communicatingwith an information-storage device. The term “downlink” refers tocommunications from a reader to an information storage device, forexample an RFID tag. The term “uplink” refers to communications from aninformation-storage device, for example an RFID tag to a reader.

RFID devices can be used for monitoring purposes, e.g., as disclosed inU.S. Pat. No. 7,268,680. This patent describes a tag unit having atransmitting unit coupled to wearable electronic banding material. AnRFID unit with a writeable memory is coupled to the transmitting unit.The band can include one or more conductors (which can be an antenna)that complete an electronic circuit. A layer of the band can include theRFID tag IC. The RFID tag can be read to determine that it isoperational. The tag can also return data indicating whether the band isstill connected to the tag IC.

RFID devices can also be used for sensing. U.S. Patent Publication No.2009/0058667 by Dixon et al. describes RFID tags connected to sensors toremotely monitor tire pressure. In this scheme, the RFID circuitrycommunicates with a sensor external to itself. This requires purchasingthe separate sensor and connecting it to the RFID tag, which adds to thecost of the tag.

U.S. Pat. No. 6,970,731 to Jayaraman et al. describes sensors formonitoring vital signs, and specifically electrical impulses produced bya living body. However, this scheme is only useful for systems thatmonitor an electrical impulse. There is a need to monitor otherconditions besides electrical signals.

Similarly, U.S. Pat. No. 7,351,191 to Mitchell et al. describes a sensorusing multiple conductors to detect distortions of an applied electricfield between the conductors. This is used to detect presence of aperson in a space, e.g., the seat of a car. Mitchell et al. describeconductors embedded into a car seat assembly and surrounded with asubstantially liquid-impervious but vapor-permeable material to permitusing a separate temperature or humidity sensor to sense the temperatureor humidity in the car and compensate for the sensed temperature orhumidity when interpreting measured electric-field data. However, thisscheme is also only useful for detecting objects that interactsufficiently with an electric field.

SUMMARY OF THE INVENTION

Existing schemes are limited in what they can sense. There is also aneed to measure environmental conditions generally. For example, thereis a need to sense the temperature of containers in which perishablegoods are shipped. There is also a need to detect exposure to hazardouschemicals that may accidentally occur. Furthermore, there are also needsto detect sequences of exposure. For example, a time-release medicineintended for the stomach can be enclosed in a capsule and swallowed. Themedicine should not be dispensed until after it has come into contactwith saliva and stomach acid, in that order. A simple pH detector with aloose threshold might incorrectly dispense the medicine if the capsulewere exposed to an acidic food or drink (e.g., apple cider vinegar), oran acidic household cleaning agent. In another environmental example, amaterial for the remediation of chemicals in water might incorrectly bereleased if splashed with water, even though it is desirable to releasethe material only after a desired amount of water is encountered for adesired length of time. There is, therefore, an ongoing need for a wayof measuring a variety of environmental conditions and tracking exposureto those conditions over time.

According to an aspect of the present invention, there is provided amethod of sensing exposure to one or more of a plurality ofenvironmental factors, comprising:

exposing a code circuit to at least some of the environmental factors,the code circuit disposed over a substrate and including a plurality ofsensor patches, each sensor patch having a respective electrical statethat changes with exposure to one of the environmental factors, so thatthe code circuit has an electrical state;

a checking step of passing an electrical excitation signal through thecode circuit, and detecting a corresponding received electrical signal,using a transceiver formed on a transceiver substrate separate from anddisposed over the substrate, wherein the transceiver includes acontroller and the received electrical signal depends on the excitationsignal and the electrical state of the code circuit;

using the controller, automatically storing the received electricalsignal or a representation thereof in a memory; and

using the controller, automatically repeating the checking and storingsteps after one or more selected time intervals.

An advantage of the present invention is that it can sense a variety ofenvironmental conditions without requiring complex external electronics.Sensor patches produce electrical signals corresponding to environmentalfactors, even when those factors do not substantially interact with anelectric field. In various aspects, any of several environmental factorscan be sensed. In various aspects, exposure to a specific sequence ofenvironmental factors can be detected. This permits detecting hazardoussequences of conditions or detecting correct function of a machine thatexposes its workpieces to a desired series of conditions.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features, and advantages of the presentinvention will become more apparent when taken in conjunction with thefollowing description and drawings wherein identical reference numeralshave been used, where possible, to designate identical features that arecommon to the figures, and wherein:

FIG. 1A is a side view of a schematic of an electronic sensing systemaccording to various aspects;

FIG. 1B is a plan view of a schematic of the electronic sensing systemof FIG. 1A;

FIG. 2 is a schematic plan of a transceiver packaged in an integratedcircuit and related components according to various aspects;

FIG. 3 is an elevational cross-section of sensor patches in a patchstack on substrate according to various aspects;

FIG. 4A is an elevational cross-section, and FIG. 4B a plan, of a sensorpatch according to various aspects;

FIG. 5 is an isometric view of an electronic sensing system according tovarious aspects;

FIG. 6 is an elevational cross-section of portions of an electronicsensing system according to various aspects;

FIGS. 7 and 8 are schematics of electronic sensing systems according tovarious aspects;

FIG. 9 shows methods of sensing exposure to one or more of a pluralityof environmental factors;

FIGS. 10A and 10B are elevational cross-sections of portions ofelectronic sensing systems according to various aspects;

FIG. 11 is an isometric view of a flow surface according to variousaspects;

FIG. 12 is a block diagram of an RFID system according to variousaspects; and

FIG. 13 is a block diagram of a passive RFID tag according to variousaspects.

The attached drawings are for purposes of illustration and are notnecessarily to scale.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, some aspects will be described in termsthat would ordinarily be implemented as software programs. Those skilledin the art will readily recognize that the equivalent of such softwarecan also be constructed in hardware. Because communications algorithmsand systems are well known, the present description will be directed inparticular to algorithms and systems forming part of, or cooperatingmore directly with, systems and methods described herein. Other aspectsof such algorithms and systems, and hardware or software for producingand otherwise processing the data involved therewith, not specificallyshown or described herein, are selected from such systems, algorithms,components, and elements known in the art. Given the systems and methodsas described herein, software not specifically shown, suggested, ordescribed herein that is useful for implementation of any aspect isconventional and within the ordinary skill in such arts.

FIG. 1A is a side view, and FIG. 1B, a plan, of a schematic of anelectronic sensing system according to various aspects. FIG. 1A is shownalong the line 1A-1A in FIG. 1B, except for the components oftransceiver 20. These components are shown schematically.

Electronic sensing system 5 includes substrate 10 having detectionregion 9. Transceiver 20 is formed on transceiver substrate 21 separatefrom substrate 10. Transceiver substrate 21 (and thus transceiver 20) isaffixed to substrate 10. Code circuit 16 is separate from transceiver 20and disposed over the substrate.

Transceiver 20 includes an output electrical-connection pad 12 (FIG. 1B)and an excitation circuit 22 adapted to provide an excitation signal tooutput pad 12. Output electrical-connection pad 12 is an output pad formaking an electrical connection, i.e., a pad adapted to be connected toa conductor to transfer current between the pad and the conductor. Aplurality of output pads 12 or excitation circuits 22 can be used in anycombination; FIG. 1B shows an example of multiple output pads 12connected to a single excitation circuit 22. Transceiver 20 alsoincludes input electrical-connection pad 14 and detection circuit 24connected to input pad 14. Input electrical-connection pad 12 is aninput pad for making an electrical connection, i.e., a pad adapted to beconnected to a conductor to transfer current between the pad and theconductor. Multiple input pads 14 or detection circuits 24 can be usedin any combination; e.g., as shown, multiple input pads 14 connected toone detection circuit 24. The terms “output” and “input” do notconstrain the direction or magnitude of current flow across outputelectrical-connection pad 12 or input electrical-connection pad 14.

Interface 26 is responsive to downlink signal 80 received from reader 89to transmit uplink signal 82 representing the electrical state of inputpad 14 to reader 89. Interface 26 can also transmit uplink signal 82spontaneously or autonomously, e.g., at regular intervals. If multipleinput pads 14 are present, uplink signal 82 can represent the state ofone or more input pads 14, and one or more uplink signals 82 can betransmitted. The term “reader” here refers to any electronic devicecapable of causing transceiver 20 to respond with the information fromcode circuit 16, e.g., an RFID reader.

The term “pad” refers to a conductor that is designed to interface witha device other than transceiver 20 and that has a designated function inthat interface. Pads are not designed to directly connect circuitelements within transceiver 20 unless other conductive material is addedoutside transceiver 20 (e.g., sensor patch 30). No particular form ofpad (leg, lead, ball, bump, or other) is required.

Code circuit 16 (FIG. 1B) includes sensor patch 30 disposed oversubstrate 10 at least partly in detection region 9. Sensor patch 30 hasan electrical state that changes with exposure to one or morecorresponding environmental factors. In various aspects, sensor patch 30is electrically conductive in an initial electrical state, i.e., beforeexposure to a corresponding environmental factor. Output pad 12 andinput pad 14 are electrically connected to code circuit 16. Code circuit16 can be formed directly on substrate 10 or on layers (e.g.planarization layer 11) formed on the substrate 10. Layer 11 can be aspin-coated planarization layer or a conformal coating. Code circuit 16can include active or passive elements such as resistors, conductors,capacitors, inductors, and transistors, for example thin-filmtransistors.

The term “environmental factor” refers to a substance or condition thatmay be present in an environment to which sensor patch 30 in detectionarea 9 is exposed. An “environment” is not necessarily the biosphere ofthe Earth, but can be any volume with measurable physical, chemical, orbiological properties. For example, the environmental factor can betemperature, humidity, pressure, or pH of a fluid in contact with sensorpatch 30. The environmental factor can also be acceleration, altitude,or mechanical abrasion. The environmental factor can also be a chemicalreaction to fluids or gases. The environmental factor can also be amechanical stress or strain, such as that induced during abrasion,cutting, or punching, in response to mechanical forces of variousstrengths and velocities. The environmental factor can be a liquid or agas.

The environmental factor can also be the presence or absence of asubstance in the fluid (e.g., a specific virus or chemical). In variousaspects, the substance is a chemical, organism, microorganism, or virus.The fluid can be a bodily fluid (e.g., blood, phlegm, bile, lymph, orurine). In various aspects, the environment is the environment of aliving organism, such as a human body or animal. The environment can bethe Earth's atmosphere, hydrosphere, or lithosphere.

Since sensor patch 30 changes electrical state with exposure to acorresponding environmental factor, and output pad 12 and input pad 14are connected to code circuit 16 including sensor patch 30, detectioncircuit 24 detects an electrical state of input pad 14 in response tothe excitation signal from excitation circuit 22 and the electricalstate of sensor patch 30.

For example, output pad 12 can be electrically connected to input pad 14through sensor patch 30, and the DC impedance (resistance) of sensorpatch 30 can change with exposure to the environmental factor. Theexcitation signal can be a fixed voltage or bias across input pads 14and output pads 12, and detection circuit 24 can include an ammeter(e.g., a Hall-effect current sensor such as the ALLEGRO ACS712) tomeasure the resulting current through code circuit 16. Resistance isthen impressed voltage divided by measured current. Alternatively,excitation circuit 22 can supply a fixed current as the excitationsignal, and detection circuit 24 can hold the voltage of input pad 14fixed. Detection circuit 24 can then measure the voltage on output pad12. Resistance is the quotient of the difference between the impressedvoltage and the measured voltage and the impressed current. Detectioncircuit 24 can include an analog-to-digital converter (ADC) to measurecurrent or voltage.

Alternatively, sensor patch 30 can be a transmitting antenna (or part ofone) connected to output pad 12, and a corresponding receiving antennacan be connected to input pad 14. Sensor patch 30 can detune thetransmitting antenna with exposure to the environmental factor so thatthe ratio of power received to power transmitted changes with exposure.The excitation signal can be an RF signal, e.g., a carrier, and theelectrical state of input pad 14 can be the relative received powerafter the excitation signal was transmitted by sensor patch 30. Codecircuit 16 can provide a DC path between output pad 12 and input pad 14,or not. Code circuit 16 can include, e.g., a resonant tank circuit ofwhich sensor patch 30 forms part. Code circuit 16 has an electricalstate correlated with the electrical states of sensor patches 30 in codecircuit 16.

Layer stack 3 is disposed over sensor patch 30 in detection region 9.Layer stack 3 includes one or more layers 2A, 2B, 2C in a selectedorder. For example, layer stack 3 can include a plurality of layers 2A,2B, 2C. The selected order in the example shown is from top to bottom(2C, 2B, 2A); for concentric systems with the sensor patch on theinside, the order is outside-to-inside. (The selected order can also beopposite as long as consistency is maintained.) Each layer 2A, 2B, 2C issubstantially electrically insulating (e.g., >10⁶× the resistance ofsensor patch 30). Layers 2A, 2B, 2C can be assembled in the selectedorder to form layer stack 3, then layer stack 3 can be deposited as aunit over substrate 10. Alternatively, each layer 2A, 2B, 2C can bedeposited over substrate 10 individually, with the layers beingdeposited in the reverse of the selected order.

Each layer 2A, 2B, 2C is susceptible to a respective environmentalfactor. “Susceptible” means that each layer 2A, 2B, 2C (as well assensor patch 30) changes properties, e.g., mechanically or chemically,on exposure to the environmental factor (examples are given below withrespect to the term “burn-through;” “susceptibility” means at least thateffects that eventually result in burn-through can occur). Layers 2A,2B, 2C and sensor patch 30 can corrode, dissolve, change between formsof the same molecule, react, disintegrate, explode, burn, melt, freeze,or otherwise change on exposure to the factor. As used herein,“susceptibility” to an environmental factor refers to both whether alayer 2A, 2B, 2C or sensor patch 30 is susceptible to the factor and towhat extent it is susceptible (e.g., reaction rate or requirement forcatalysts). As used herein, “higher susceptibility” layers changeelectrical properties more quickly, or in response to smaller amounts ofexposure, than “lower susceptibility” layers. As used herein, if acertain property of a layer changes in response to an environmentalfactor, the layer is said to have that property susceptible to thatfactor. For example, calcium changes its conductivity on exposure towater, so calcium is described as having a conductivity susceptible towater.

In some aspects, exposure to the corresponding environmental factorcauses a layer to change from blocking an environmental factor (to whichthe layer can be susceptible or not) to permitting that environmentalfactor through the layer. This is referred to herein as “burn-through,”but no requirement of mechanical failure or chemical oxidation (burning)is implied. A “burned-through” layer has been, in whole or in part,corroded, dissolved, moved, rearranged, caused to bead up, or otherwiseremoved, penetrated, or permeated, by an environmental factor to whichthat layer is susceptible. As a result, that environmental factor orother environmental factors can pass through the burned-through layer.The environmental factor that caused the burn-through does notnecessarily pass through the burned-through layer; for example, theenvironmental factor can be a catalyst that catalyzes a reaction thatburns through the layer so a factor other than the catalyst itself canpass. In an example, even the formation of a pinpoint void penetratingthrough a layer can be burn-through of that layer.

Layers 2A, 2B, 2C can be susceptible to the same environmental factor ordifferent environmental factors, or any combination. As a result, sensorpatch 30 changes electrical state in response to exposure of layer stack3 to the respective environmental factors of the one or more layers 2A,2B, 2C in the selected order (2C, 2B, 2A) and subsequent exposure ofsensor patch 30 to the corresponding environmental factor (to whichsensor patch 30 or a layer therein is susceptible). The one or morelayers 2A, 2B, 2C in layer stack 3, plus sensor patch 30, togetherresult in the electrical state of input pad 14 changing when detectionregion 9 has been exposed to a plurality of environmental factors inorder from environment 320. Multiple environmental factors can also bepresent in environment 320 concurrently, so that when, e.g., layer 2Cburns through due to exposure to the corresponding environmental factor,layer 2B immediately begins to degrade due to exposure to itscorresponding environmental factor.

In various aspects, layer stack 3 includes exactly one layer 2A, i.e.,includes layer 2A and no other layers. Sensor patch 30 also includes alayer (not shown) susceptible to the corresponding environmental factor.Seal 4 (FIG. 1A) is lower in susceptibility to the respectiveenvironmental factors of layer 2A and sensor patch 30 than the layer 2Aand sensor patch 30. Seal 4 is arranged so that sensor patch 30 ispermitted to be exposed to the respective environmental factor onlythrough a void in layer 2A. A “void” is any aperture or region throughwhich the respective environmental factor can pass. It is not requiredthat a “void” be actually empty of material. For example, aliquid-permeable area in an otherwise liquid-impermeable layer is a“void” as used herein. In the example shown, seal 4 covers the edges ofsensor patch 30 and layer 2A, leaving only the top, center area of layer2A exposed to environment 320. As a result, sensor patch 30 is notexposed to environment 320 until layer 2A has burned through. In anotherexample, the environmental factor is heat. A void is an area in a layerof appreciably higher thermal conductivity (e.g., 20% greater) than therest of the layer. Alternatively, the entirety of a layer can be a voidwith respect to a seal, as discussed below with respect to FIGS.10A-10B.

In various aspects, layer stack 30 includes first-exposed layer 2C and aplurality of buried layers 2B, 2A arranged between first-exposed layer2C and substrate 10. Seal 4A is lower in susceptibility to each of therespective environmental factors than the respective layers 2C, 2B, 2Ain the layer stack. Seal 4A is arranged so that each buried layer 2B, 2Ais permitted to be exposed to the respective environmental factor onlythrough respective void(s) in the one or more layer(s) 2C, 2B fartherfrom substrate 10 than that buried layer 2B, 2A. For example, buriedlayer 2B is permitted to be exposed to environment 320 only through avoid in layer 2C. Buried layer 2A is permitted to be exposed toenvironment 320 only through respective voids in layers 2C and 2B.Sensor patch 30 is permitted to be exposed to environment 320 onlythrough respective voids in layers 2C, 2B, and 2A. Environment 320 isdefined so that layers 2A, 2B, 2C that are permitted to be exposed tothe corresponding environmental factor will be exposed to that factor ifthat factor is present in environment 320. Environment 320 does notinclude volumes from which environmental factors cannot reach the layers(e.g., layers 2A, 2B, 2C) to which they are susceptible.

In various aspects, electronic sensing system 5 is used to validateoperation of processing machinery that exposes items to a series ofenvironmental factors. For example, a machine can expose an item to aseries of temperatures and chemicals to process it (e.g., aprinted-circuit-board placement machine, which exposes a printed-circuitboard to a specific sequence of heat, flux, solder, and heat). Layerstack 3 (or a patch stack, as described below) can include layers(patches) susceptible to those factors in order top to bottom, andelectronic sensing system 5 including layer stack 3 (or a patch stack)can be passed through the machine. If the correct sequence is provided,layer stack 3 will burn through and sensor patch 30 will changeelectrical state to indicate success.

Still referring to FIGS. 1A and 1B, in various aspects, detectioncircuit 24 includes circuitry, e.g., controller 88, that responds tosignals on input pads 14, analyzes the signals to produce information,and temporarily stores the information, e.g., in memory 42, which can bean SRAM. The information is then accessible for transmission byinterface 26. Interface 26 reads the temporarily stored information andtransmits it as an uplink signal 82 through antenna 28. Controller 88can also read the stored information and transmit it through interface26. The information read can be that stored in memory 42. Antenna 28 canbe disposed over or attached to substrate 10. Antenna 28 can besubstantially coplanar with substrate 10 or protruding or extendingtherefrom. The information can also be transmitted concurrently with itsproduction by detection circuit 24, so that no temporary storage isrequired. In various aspects, transceiver 20 is a radio-frequencyidentification (RFID) transceiver. Transceiver 20 and reader 89 cancommunicate using standard protocols, such as EPCglobal Class-1 Gen-2RFID, BLUETOOTH, WIFI, Ethernet, Aloha, or GSM, or custom protocols. Theterm “transceiver” as used herein includes transponders that respond toqueries.

Substrate 10 can be a commercially available substrate, e.g., glass,plastic, or metal. Substrate 10 can be a packaging material, includingbut not limited to paper, cardboard, wood, plywood, laminates,fiberboard, plastic, or a packaging material coated in polymer.Substrate 10 can be a disposable material and can have formed thereon aplanarization layer 11 to facilitate the construction and performance ofthe code circuit 16. Layer 11 can also seal or smooth substrate 10. Aseal 13 (e.g., a spin-coated layer) can be provided over portions ofcode circuit 16 to protect those portions (e.g., separately-placeddiscrete components). In various aspects, transceiver 20 is alsoencapsulated or otherwise sealed against environmental factors toimprove its robustness. Commercial methods are known for manufacturing,cutting, shaping, and folding substrate materials, for example forpackaging containers.

Transceiver 20 can be an integrated circuit, for example formed on asemiconductor transceiver substrate 21 such as silicon or galliumarsenide and can be crystalline, polycrystalline, or amorphous.Transceiver substrate 21 can be a circuit substrate that includes one ormore circuits formed on or in the circuit substrate. Alternatively,transceiver substrate 21 can be formed on a non-semiconductor substratewith a semiconductor coating such as crystalline, polycrystalline, oramorphous semiconductor materials, for example silicon, or include oxidematerials such as aluminum oxide, aluminum zinc oxide, or other oxidematerials in which thin-film circuits (e.g., thin-film transistors) orpassive electrical elements can be formed. Transceiver substrate 21 canbe affixed with an adhesive to substrate 10 either as part ofplanarization layer 11 or as a separate layer (not shown). Transceiver20 can be formed on a silicon wafer, packaged in a ball-grid array (BGA)package, and placed on a printed-circuit board substrate 10 using anautomated pick-and-place machine. The transceiver IC can also besupplied as a bare die, e.g., a known-good die (KGD), and bondeddirectly to substrate 10. Alternatively, transceiver 20 can be formed onor over substrate 10 by printing semiconductor materials and conductorsusing various methods known in the art, for example inkjet depositionmethods.

Transceiver 20 can include controller 88 to command excitation circuit22 and detection circuit 24 and to communicate with interface 26.Controller 88 can include a CPU, MPU, FPGA, PLD, PLA, PAL, ASIC, orother logic or processing device. The excitation signal can be producedat regular time intervals, time intervals based on past electrical-statereadings, or in response to a reading from a sensor (not shown)connected to controller 88. The excitation signal can also be producedin response to external events, such as human actuation of a usercontrol or the receipt of an external signal (e.g., SYNC). Controller 88can be connected to, or include, memory 42, which can be volatile ornonvolatile, e.g., RAM, SRAM, DRAM, ROM, Flash, EPROM, or EEPROM. Memory42 can store access keys, thresholds, or other values; various examplesare discussed herein.

Various aspects described herein include layer stacks including multiplelayers, patch stacks including multiple sensor patches, or stacks oflayers or sensor patches over another sensor patch. Layers and sensorpatches can be used in various combinations described herein, sodepictions of layers in the figures can also represent sensor patches,and vice versa, unless otherwise stated herein.

FIG. 2 is a plan of transceiver 20 packaged in an integrated circuitwith input and output electrical interconnection pads 14, 12,respectively. Input pads 14, output pads 12, detection circuit 24, andexcitation circuit 22 are as shown in FIGS. 1A and 1B.

In various aspects, input pads 14 or output pads 12 are provided aspins, bumps, pads, leads, or other contact types found in integratedcircuits of various formats, for example pin-grid arrays, ball-gridarrays, small-outline packages, or thin small-outline packages. Input oroutput pads 14, 12 provide an externally accessible electricalconnection to the circuits in transceiver 20. In various aspects, asingle pad serves as an output pad 12 and an input pad 14, eithersimultaneously or sequentially, as is discussed below.

In various aspects, transceiver 20 includes, or is electricallyconnected to, one or more electrical connectors 56. Interface 26communicates with electrical connectors 56. Connectors 56 can be, e.g.pads, sockets, pogo pins, bond wires, or pins, adapted to mechanicallycontact one or more electrodes 57 separate from the transceiver to formone or more electrical connections between electrical connectors 56 andelectrodes 57. In the example shown, electrodes 57 are pogo pins and theelectrical connectors are pads. Transceiver 20 can be interrogatedthrough wired readers, probe cards, communications controllers, or otherinterrogation devices.

In various aspects, transceiver 20 is connected to RF antenna 28, to oneplate of a capacitor, or to an inductor. This permits wireless datatransfer. In various aspects, interface 26 includes optional securitycircuit 74 that controls access to information read from code circuit16. Security circuit 74 includes storage for an enablement signal. Ifthe stored enablement signal is present or has the correct value,interface 26 is permitted to transmit information received fromdetection circuit 24. If the enablement signal is not present or isincorrect, interface 26 is not permitted to transmit information fromdetection circuit 24. The enablement signal can be providedelectronically or by using software. In an example, a password (or othercryptographic secret) is supplied to security circuit 74 through acomputer-mediated graphical user interface or a physical switch.Security circuit 74 compares the received password to a stored secret(e.g., a password or one-time pad key) and sets the enablement signal ifthe received password and the secret password match. In other aspects,security circuit 74 calculates a cryptographic hash of a known secretpassword plus salt, a challenge or nonce from reader 89 (FIG. 1A), orboth. Security circuit 74 compares the calculated hash with a hashreceived from reader 89, and enables if the hashes match. Securitycircuit 74 can include logic or software to perform public- orprivate-key encryption, block or stream ciphering, key exchange,hashing, compression or decompression, or any combination of those.

FIG. 3 is an elevational cross-section of sensor patches 30, 310 in apatch stack on substrate 10 according to various aspects. Substrate 10and sensor patches 30, 310 are shown spaced apart for clarity. They canbe stacked directly on each other. Sensor patch 30 haselectrically-conductive layer 302C that is susceptible to thecorresponding environmental factor, and optional electrically-insulatinglayer 309Z. Sensor patch 310 has electrically-conductive layer 312C andoptional electrically-insulating layer 319Z. In an example, since layers302C, 312C are susceptible to respective environmental factors, sensorpatches 30, 310 changes electrical state (e.g., impedance) when exposedto the respective environmental factor.

Optional electrically-insulating layer 309Z is arranged betweenelectrically-conductive layer 302 of sensor patch 30 andelectrically-conductive layer 312C of adjacent second sensor patch 310in a stack of sensor patches. Layer 309Z electrically insulatesconductive layers 302C, 312C from each other. Electrically-insulatinglayer 309Z is susceptible to the corresponding environmental factor ofsensor patch 30. Electrically-insulating layer 319Z, likewise, insulateslayer 312C from a layer in a sensor patch (not shown) above patch 310.Electrically-insulating layer 319Z is susceptible to the correspondingenvironmental factor of sensor patch 310. Patches 30, 310 can besusceptible to the same environmental factor or different environmentalfactors. In aspects using a patch stack, each patch in the stack can besusceptible to a respective environmental factor. The layers can be thesame size or different sizes, in any combination. FIG. 3 showselectrically-conductive layers 302C, 312C. Electrically-insulatinglayers can also be used, e.g., as discussed below with reference toFIGS. 4A-4B.

Sensor patches 30, 310, and layers 302C, 309Z, 312C, 319Z therein, canbe formed in a variety of ways. In various aspects, conductive inks arepattern-wise applied to the substrate 10 and connected to the input andoutput pads 14, 12 (FIG. 2). This can be done using, e.g., an inkjetprinter or printhead or a flexographic or gravure printer. Sensor patch30 can include conductive particles and non-conductive binder particles.Non-conductive particles can be removed or set using chemical methods orexposure to radiation (e.g., ultraviolet light). Patterned conductiveinks can thus be cured to form code circuit 16 (FIG. 1B) includingsensor patch 30. Sensor patch 30 includes conductive wires, resistors,capacitors, inductors, or other passive electrical devices that storeinformation in code circuit 16 to be retrieved when code circuit 16 isqueried with an excitation signal.

FIG. 4A is an elevational cross-section of sensor patch 30 according tovarious aspects. FIG. 4B is a plan of sensor patch 30. Seal 4 andenvironment 320 are as discussed above with reference to FIG. 1A. Sensorpatch 30 has electrically-insulating layer 403Z that is susceptible tothe corresponding environmental factor, and conductor 405C. Conductor405C is arranged on the side of layer 403Z closer to substrate 10.Conductor 405C can be disposed over or embedded within layer 403Z, orcan protrude therefrom. Layer 403Z and conductor 405C can be the samesize or different sizes.

As shown, in these aspects, seal 4 wraps around the edges of layer 403Zand covers a small area of the top of layer 403Z. As a result, theenvironmental factor in environment 320 cannot contact or act on layer403Z through seal 4. The environmental factor therefore cannot contactor act on conductor 405C until layer 403Z burns through. As shown inFIG. 4B, seal 4 leaves window 403W open. Window 403W is an openingthrough which the environmental factor can contact or act on the topsurface of layer 403Z.

In various aspects, conductor 405C is susceptible to the sameenvironmental factor as layer 403Z. Therefore, after layer 403Z burnsthrough, conductor 405C will burn through if exposure to theenvironmental factor continues.

In other aspects, layer 403Z is susceptible to a first environmentalfactor. Conductor 405C is susceptible to a second environmental factordifferent from the first environmental factor. After layer 403Z burnsthrough from exposure to the first environmental factor, conductor 405Cwill burn through only if the second environmental factor is present.For example, calcium is conductive, but reacts with water to form CaOand Ca(OH)₂, both of which are non-conductive. If water vapor is thesecond environmental factor and is always present in environment 320,the material of layer 403Z can be selected to be susceptible to a firstenvironmental factor without regard to the electrical properties of thatmaterial. Conductor 405C will burn through once the first environmentalfactor has burned through layer 403Z. This permits inexpensivelydetecting environmental factors that do not significantly affectelectrical properties, e.g., elevated temperatures within ranges atwhich conductor 405C is a low-resistivity solid. In another example,this permits detecting low levels of moisture (first environmentalfactor) in an environment corrosive to metals (second environmentalfactor). Layer 403Z protects conductor 405C from premature corrosion.

FIG. 5 is an isometric view of an electronic sensing system according tovarious aspects. Substrate 10 has detection region 9, as discussed abovewith respect to FIG. 1B.

Transceiver 20 is formed on transceiver substrate 21 (FIG. 1A) separatefrom substrate 10 and affixed to substrate 10. Transceiver 20 includesan output electrical-connection pad, an excitation circuit adapted toprovide an excitation signal to the output pad, an inputelectrical-connection pad, a detection circuit connected to the inputpad, and an interface responsive to a downlink signal to transmit anuplink signal representing the electrical state of the input pad, asshown in FIGS. 1A, 1B, and 2. Input electrical-connection pad 14 isshown in this figure. In various aspects, code circuit 16 (FIG. 1B)electrically connects output electrical-connection pad 12 (FIG. 1B) toinput electrical-connection pad 14 through sensor patches 530A, 530B,530C. That is, output electrical-connection pad 12 is electricallyconnected to input electrical-connection pad 14 through the plurality ofsensor patches 530A, 530B, 530C.

Patch stack 503 is disposed over substrate 10 at least partly indetection region 9. Patch stack 503 includes a plurality ofelectrically-conductive sensor patches 530A, 530B, 530C in a selectedorder. Each sensor patch 530A, 530B, 530C has a conductance susceptibleto a respective environmental factor. The conductances can besusceptible to the same environmental factor or to differentenvironmental factors, in any combination, and the magnitude ofsusceptibility can be the same or different for each sensor patch 530A,530B, 530C, in any combination. Conductance of a sensor patch 530A,530B, 530C can change because the electrical conductivity, size, orshape of the sensor patch changes. In an aspect, sensor patches 530A,530B, 530C can be spatially distributed over substrate 10 rather thanvertically stacked. In this configuration, the same environmental factor320 can affect a plurality of, or all of, the sensor patches 530A, 530B,530C at the same time. In such an aspect, the sensor patches 530A, 530B,530C can have different susceptibilities to environmental factors inenvironment 320. This is discussed further below with respect to FIG. 7.

The output electrical-connection pad of transceiver 20 is electricallyconnected to the input electrical-connection pad through some or all ofthe sensor patches 530A, 530B, 530C in parallel electrically. Thedetection circuit in transceiver 20 therefore detects an electricalstate of the input pad in response to the excitation signal and therespective conductances of the sensor patches. In the example shown,sensor patches 530A, 530B, 530C are electrically connected totransceiver 20 through conductors 512, 514. Sensor patches 530A, 530B,530C function as resistors wired in parallel, so as each is affected bythe environmental factor in environment 320, the parallel resistanceseen by transceiver 20 across conductors 512, 514 changes. Transceiver20 detects this change and determines that environment 320 contains afactor to which at least one of the sensor patches 530A, 530B, 530C issusceptible.

Sensor patches 530A, 530B, 530C can be electrically isolated from eachother but wired in parallel, as shown here. Sensor patches 530A, 530B,530C can also be electrically connected at the surfaces where theyinterface to form a single resistive element. The resistance of thiselement will vary as the conductance of each sensor patch 530A, 530B,530C changes. The parallel-wiring configuration and single-resistorconfiguration have similar conductances but different electricalparasitics and mechanical structures. These configurations also responddifferently to exposure of faces of sensor patches 530A, 530B, 530C toenvironment 320.

Still referring to FIG. 5, and also referring back to FIG. 1, in variousaspects, the electrical state of input electrical-connection pad 14represents a detected resistance (DC impedance) of sensor patches 530A,530B, 530C wired in parallel. Transceiver 20 further includes acontroller (controller 88, FIG. 1A) and a memory (memory 42, FIG. 1A)storing a plurality of thresholds. Controller 88 compares the detectedresistance to one or more of the thresholds. Controller 88 automaticallytransmits uplink signal 82 (FIG. 1) whenever the detected resistancecrosses one of the thresholds. In various aspects, controller 88periodically measures the detected resistance and stores the result inmemory. If the next reading differs from the previous reading by morethan a selected amount, controller 88 transmits uplink signal 82.

FIG. 6 is an elevational cross-section of an electronic sensing systemaccording to various aspects. Substrate 10, environment 320, patch stack503, and sensor patches 530A, 530B, 530C are as discussed above withreference to FIG. 5. Seal 4 is as discussed above with reference toFIGS. 4A and 4B. Seal 4 is arranged so that the environmental factoraffects sensor patch 530A, then 530B, then 530C as each higher-up patchburns through.

Specifically, patch stack 503 includes first-exposed sensor patch 530Aand a plurality of buried sensor patches 530B, 530C. Buried sensorpatches 530B, 530C, of which there can be any number, are arrangedbetween first-exposed sensor patch 530A and substrate 10. Seal 4 islower in susceptibility to each of the respective environmental factorsthan the respective sensor patches 530A, 530B, 530C in the patch stack.Seal 4 is arranged so that each buried sensor patch 530B, 530C ispermitted to be exposed to the respective environmental factor onlythrough a void in one or more sensor patches 530A, 530B farther from thesubstrate than that buried sensor patch 530B, 530C. In this example,sensor patch 530B is permitted to be exposed to environment 320 onlyafter sensor patch 530A burns through. Sensor patch 530C is permitted tobe exposed to environment 320 only after sensor patches 530A and 530Bburn through. In this way, the resistance of the parallel combination ofsensor patches 530A, 530B, 530C can change gradually as burn-throughoccurs.

FIG. 7 is a plan of an electronic sensing system according to variousaspects. Antenna 28 and substrate 10 with detection region 9 are asdiscussed above with respect to FIG. 1B.

Transceiver 20 is formed on a transceiver substrate separate from thesubstrate and affixed to the substrate, as described above withreference to FIG. 1A. Transceiver 20 includes outputelectrical-connection pad 12, excitation circuit 22 adapted to providean excitation signal to output pad 12, input electrical-connection pad14, detection circuit 24 connected to the input pad, and interface 26responsive to a downlink signal to transmit an uplink signalrepresenting the electrical state of input pad 14.

Code circuit 16 includes a plurality of electrically-conductive sensorpatches 30A, 30B disposed over substrate 10, each sensor patch 30A, 30Bdisposed at least partly in detection region 9. Each sensor patch 30A,30B has a conductance susceptible to a respective environmental factor.

Sensor patches 30A, 30B are distributed over substrate 10 so that theyare exposed to an external environmental factor substantiallycontemporaneously. For example, the sensor patches 30A, 30B can be nextto each other and not separated by baffles or other barriers so that ifsubstrate 10 is dipped in water, all the sensor patches 30A, 30B will bemoistened at substantially the same time. Sensor patches 30A, 30B canpartially overlap each other.

Output pad 12 is electrically connected to input pad 14 through sensorpatches 30A, 30B in series. Detection circuit 24 thus detects anelectrical state of input pad 14 in response to the excitation signaland the respective conductances of sensor patches 30A, 30B. This permitsdetecting any of several environmental factors to which detection region9 can be exposed. In the example shown, two sensor patches 30A, 30B areconnected in series, and each is susceptible to a respective, differentenvironmental factor. Exposure to either of the respective, differentenvironmental factors will change the conductance of the seriescombination of the two sensor patches 30A, 30B. This permits transceiver20 to detect either factor and report that one of the factors ispresent. In an example, a plurality of sensor patches 30A, 30B can beused to detect the following, respectively: temperatures below 0° C.;temperatures above 35° C., high concentrations of methane, highconcentrations of corrosive agents, and submersion. The system thusconfigured can give warning of any of those potentially-hazardousconditions.

In various aspects, a patch stack (not shown) is used in place of one ofthe sensor patches 30A, 30B, or in addition to the sensor patches 30A,30B, or any combination. A layer stack together with a conductor canalso be used instead of, or in addition to, a patch stack. A patch stackcan have sensor patches electrically connected in parallel (e.g., asshown in FIG. 5). A layer stack can have a single conductor undermultiple layers (e.g., as shown in FIGS. 3 and 4A). In an example, apatch stack is used in place of sensor patch 30B. Controller 88 (FIG.1A) will detect a significant change in resistance (e.g., an open) ifsensor patch 30A burns through or if the patches in the patch stack burnthrough in sequence. This permits detecting any one of a set ofconditions, each condition being either exposure to a singleenvironmental factor or exposure to a sequence of environmental factors.

FIG. 8 is a plan of an electronic sensing system according to variousaspects. Antenna 28 and substrate 10 with detection region 9 are asdiscussed above with respect to FIG. 1B. Transceiver 20, interface 26,output electrical-connection pad 12, and input electrical-connection pad14 are as shown in FIG. 7.

Excitation circuit 22 provides an excitation signal to output pad 12.Electrically-conductive sensor patches 30A, 30B are disposed over thesubstrate as described above with reference to FIG. 7. Output pad 12 iselectrically connected to input pad 14 through sensor patches 30A, 30Bin parallel, so that detection circuit 24 detects an electrical state ofinput pad 14 in response to the excitation signal and the respectiveconductances of the sensor patches 30A, 30B.

In various examples related to FIG. 7, a strong signal (significantchange in resistance) is produced for exposure to any of theenvironmental factors to which the sensor patches 30A, 30B aresusceptible. Various examples related to FIG. 8 can produce a weakersignal for a single burn-through, but can determine which of theenvironmental factors the system has been exposed to. In variousexamples related to FIG. 8, each sensor patch 30A, 30B has a respective,different electrical resistance. The respective electrical resistancesof the sensor patches can form a logarithmic or exponential series. Forexample, the sensor patches can have resistances of 10Ω, 100Ω, and 1000Ω(10²-10⁴), for a parallel resistance of approximately 9Ω. If the 10Ωsensor patch burns through and opens, the resistance of the parallelcombination jumps to approximately 91 ohms (˜10× change). If the 100Ωpatch opens, the parallel resistance changes to approximately 10Ω (˜11%change). If the 1000Ω patch opens, the parallel resistance changes toapproximately 9.1Ω (˜1% change).

In another example, three patches can have resistances of 16Ω, 32Ω, and64Ω (2⁴-2⁶). The parallel combinations are given in Table 1, below. R1,R2, and R3 are the three resistance values, or “open” for sensor patches30A, 30B that have burned through and are no longer electricallyconductive (e.g., >1MΩ or >10MΩ, or ∞Ω). (Patches 30A, 30B that haveonly partly burned through will have finite resistances that contributeto the parallel combination.) Rpar is the resulting parallelcombination, and Δ is the percentage difference between each row and thefirst row (all three patches 30A, 30B conducting).

TABLE 1 resistance example R1 R2 R3 Rpar Δ 16 32 64 9.14 N/A open 32 6421.33 133% 16 open 64 12.80  40% 16 32 open 10.67  17% open open 6464.00 600% 16 open open 16.00  75% open 32 open 32.00 250% open openopen ∞ ∞

The various Rpar values are far enough apart to be readilydistinguishable using measurement techniques discussed above. Othervalues of Rn can be used, e.g., values that do not form a regularsequence.

Still referring to FIG. 8, in various aspects, combinations of stacks(either patch stacks or layer stacks) and individual patches are used.In the example shown, patch stack 803 includes sensor patches 30D, 30E,and 30F stacked vertically, optionally sealed by seal 4. Sensor patches30A, 30B, 30C are shown offset in FIG. 8 so they are all visible.However, they are all in fact stacked vertically, e.g., as shown inFIGS. 5 and 6 (although some overlap or offset is permissible).Moreover, as shown in FIG. 5, sensor patches 530A, 530B, 530C areelectrically connected in parallel. In this way, controller 88 (FIG. 1A)detects a change in resistance (e.g., per Table 1) when any of severalconditions occurs. Each condition can be either exposure to a singleenvironmental factor (sensor patches 30A, 30B, or 30C and theirrespective environmental factors) or exposure to a sequence ofenvironmental factors (patch stack 803 detecting the sequence ofexposure to environmental factors to which sensor patches 30F, 30E, 30Dare susceptible, in that order).

In various examples, memory 42 (FIG. 1A) is used, as described abovewith reference to FIG. 7. The electrical state of inputelectrical-connection pad 14 represents a detected resistance of thesensor patches wired in parallel. The controller compares the detectedresistance to one or more stored thresholds and automatically transmitsthe uplink signal whenever the detected resistance crosses one of thethresholds, or whenever the difference between previous and currentreadings crosses one of the thresholds.

FIG. 9 shows methods of sensing exposure to one or more of a pluralityof environmental factors. Processing begins with optional step 905 orstep 910. An arrow with a triangular arrowhead connects a step to a stepthat can follow it. An arrow with an open arrowhead connects a step to asubstep that step can include.

In optional step 905, before exposing step 910, the sensor patches ofthe code circuit (discussed below) are disposed over the substrate bydepositing respective conductors and printing respective susceptiblelayers over the conductors. Each susceptible layer is susceptible to acorresponding one of the one or more environmental factors. Theconductors and susceptible layers can be deposited or printed using aprinter, e.g., an inkjet or electrophotographic printer. Optional step905 is followed by step 910.

In step 910, a code circuit is exposed to at least some of theenvironmental factors. The code circuit is disposed over a substrate andincludes a plurality of sensor patches, which are electrically connectedin various aspects. Each patch has a respective, specific lateralextent, and is susceptible to one or more of the environmental factors.That is, each sensor patch has a respective electrical state thatchanges with exposure to one or more corresponding one(s) of the one ormore environmental factors. The code circuit has an electrical state, asdiscussed above, related to the electrical states of the sensor patchesand their electrical connections to each other and to input and outputelectrical-connection pads. In various aspects, at least one of therespective electrical states of the sensor patches changes from highconductivity to low conductivity with exposure to the environmentalfactor. In other aspects, the change is from low conductivity to highconductivity. Various examples of sensor patches, layers, patch stacks,and layer stacks on patches are given herein and can be used withvarious aspects of this method.

In various aspects, the sensor patches are arranged in a patch stackincluding a first-exposed one of the sensor patches and one or moreburied ones of the sensor patches arranged between the first-exposedsensor patch and the substrate. The code circuit includes a seal lowerin susceptibility to each of the respective environmental factors thanthe respective sensor patches in the patch stack. The seal is arrangedso that each buried sensor patch is permitted to be exposed to therespective environmental factor only through a void in one or moresensor patches farther from the substrate than the buried sensor patch.

In various aspects, patch stacks (or layer stacks on a sensor patch),seals, and cavities are used as described below with reference to FIGS.10A-10B. In these aspects, as described below, exposing a first-exposedsensor patch to the corresponding environmental factor causes thefirst-exposed sensor patch to become fluid. At least some of theresulting liquid or gas then travels substantially according to a flowpattern into the cavity to permit a second-exposed sensor patch to beexposed to the corresponding environmental factor. Flow patterns arediscussed below with respect to FIG. 11. In various aspects,burn-through of a first-exposed sensor patch develops a void thereinthrough which a second-exposed sensor patch is permitted to be exposedto the respective environmental factor.

In various aspects, the sensor patches are electrically connected inparallel. In other aspects, the sensor patches are electricallyconnected in series. In various aspects, the sensor patches aredistributed (and can optionally overlap somewhat) over the substrate sothat they are exposed to an external environmental factor substantiallycontemporaneously. Step 910 is followed by step 920 and can includeoptional step 919.

In optional step 919, which is part of step 910, a plurality of codecircuits are contemporaneously exposed to the at least some of the oneor more environmental factors. Each code circuit is disposed over thesubstrate and includes a respective plurality of electrically-connectedsensor patches. Each sensor patch is susceptible to one of the one ormore environmental factors. Each code circuit has a respectiveelectrical state.

In various aspects, a first of the code circuits includes respectivesensor patches that are susceptible to a first subset of the pluralityof environmental factors and a second of the code circuits includesrespective sensor patches that are susceptible to a second subset of theplurality of environmental factors different from the first subset. Inthis way, each code circuit performs different tests. Optional step 919is followed by optional step 929.

In step 920, which is a checking step, an electrical excitation signalis passed through the code circuit, and a corresponding receivedelectrical signal is detected. This is done using a transceiver formedon a transceiver substrate separate from and disposed over thesubstrate. The transceiver includes a controller, as discussed above.The received electrical signal depends on the excitation signal and theelectrical state of the code circuit. Step 920 is followed by step 930and can include optional step 925 or optional step 929.

In optional step 925, which is part of step 920, the controllerautomatically compares the received electrical signal with a selectedcriterion. If the signal corresponds to the criterion, the controlleractivates an actuator. The criterion can be that an event happened ordid not happen, as indicated by the received electrical signal, or thatthe received electrical signal crossed a threshold or entered a certainrange, or other digital or analog criteria or combinations thereof. Inan example, the actuator is adapted to dispense a drug when activated.For example, the actuator can dispense the drug into thegastrointestinal tract or circulatory system of a human or animal.

In optional step 929, which is part of step 920, a respective electricalexcitation signal is passed through each code circuit. A respectivereceived electrical signal is detected for each code circuit. Optionalstep 929 is followed by optional step 939.

In step 930, using the controller, the received electrical signal or arepresentation thereof is automatically stored in a memory. Step 930 isfollowed by decision step 940 and can include optional step 935 oroptional step 939.

In optional step 935, which is part of step 930, the controller receivesa downlink signal and, in response, transmits an uplink signalrepresenting the stored received electrical signal(s) orrepresentation(s) thereof. This is represented graphically as followingstep 930 but can happen at any time.

In optional step 939, which is part of step 930, using the controller,the respective received electrical signals or respective representationsthereof, in any combination, are automatically stored in the memory.

Decision step 940 decides whether a selected time interval has elapsed.If so, the next step is step 920. In this way, the controller is used toautomatically repeat the checking and storing steps after one or moreselected time intervals.

According to various aspects, an electronic sensing system includes asubstrate with a detection region. A transceiver formed on a transceiversubstrate separate from the substrate is affixed to the substrate. Thetransceiver has one or more output electrical-connection pad(s), anexcitation circuit adapted to provide an excitation signal to the outputpad(s), one or more input electrical-connection pad(s), and a detectioncircuit (which can have multiple inputs) connected to the input pad(s).A code circuit separate from the transceiver is disposed over thesubstrate at least partially in the detection region. The code circuithas a plurality of conductors and a plurality of electrically-insulatinglayers. The conductors and layers are arranged to form a layer stack.Each layer is susceptible to a respective environmental factor, so thatthe conductors change respective electrical states in response toexposure of the layer stack to the respective environmental factors. Notall factors necessarily affect all conductors. Each conductor iselectrically connected to one of the output pad(s) and one of the inputpad(s). The detection circuit detects an electrical state of each of theinput pad(s) in response to the excitation signal and the electricalstate of the connected conductor(s). The transceiver includes aninterface responsive to a downlink signal to transmit an uplink signalrepresenting the electrical state(s) of the input pad(s).

According to various aspects, an electronic sensing system includes asubstrate with a detection region. A transceiver formed on a transceiversubstrate separate from the substrate is affixed to the substrate. Thetransceiver has an output electrical-connection pad, an excitationcircuit adapted to provide an excitation signal to the output pad, aninput electrical-connection pad, and a detection circuit connected tothe input pad. A code circuit separate from the transceiver is disposedover the substrate at least partially in the detection region. The codecircuit includes a conductor and a plurality of electrically-insulatinglayers disposed over or under (or each at different points) theconductor. Each layer is susceptible to a respective environmentalfactor, so that the conductor changes electrical state in response toexposure of any of the layers to the respective environmental factors.The layers are distributed (and can partially overlap) over thesubstrate so that they are exposed to an external environmental factorsubstantially contemporaneously. The conductor is electrically connectedto the output pad and the input pad so that the detection circuitdetects an electrical state of the input pad in response to theexcitation signal and the electrical state of the conductor. Thetransceiver further includes an interface responsive to a downlinksignal to transmit an uplink signal representing the electrical state(s)of the input pad(s).

According to various aspects, an electronic sensing system includes asubstrate with a detection region. A transceiver formed on a transceiversubstrate separate from the substrate is affixed to the substrate, thetransceiver including an output electrical-connection pad, an excitationcircuit adapted to provide an excitation signal to the output pad, aninput electrical-connection pad, a detection circuit connected to theinput pad. A code circuit separate from the transceiver is disposed overthe substrate at least partially in the detection region, the codecircuit including a plurality of conductors and a correspondingplurality of electrically-insulating layers disposed over or undercorresponding conductors. The conductors and layers do not have to be in1-to-1 relationship; one conductor can be connected to one or morelayers, or one layer can be connected to one or more conductors, or anycombination. Each layer is susceptible to a respective environmentalfactor, so that each conductor changes respective electrical state inresponse to exposure of a corresponding one of the layers to therespective environmental factor. The conductors are connected inparallel between the output pad and the input pad. The detection circuitdetects an electrical state of the input pad in response to theexcitation signal and the electrical state of the connected conductors.The transceiver further includes an interface responsive to a downlinksignal to transmit an uplink signal representing the electrical state ofthe input pad. In various examples, the resistances of various of theconductors or layers are different from each other.

FIGS. 10A and 10B are elevational cross-sections of portions ofelectronic sensing systems according to various aspects. Seal 4,substrate 10, and environment 320 are as discussed above with referenceto FIG. 6. In the discussion of FIGS. 10A and 10B, layers and layerstacks are referred to. These can also be sensor patches and sensorpatch stacks, e.g., as described above with reference to FIG. 5. Layer1030A, which can be a sensor patch, can be conductive or non-conductive.

Seal 1004 is a seal similar to seal 4, or a portion of seal 4. Seals 4,1004 are labeled differently for clarity of reference in thisdiscussion. Seals 4, 1004 are lower in susceptibility to the respectiveenvironmental factors of layers 1030A, 1030B than layers 1030A, 1030B,respectively.

In various aspects, only a sensor patch and a single layer are used.Layers 1030B, 1030C are not present, and layer 1030A is adjacent tosensor patch 1030D. Seals 4, 1004 are arranged so that the sensor patch(e.g., layer 1030D) is permitted to be exposed to the respectiveenvironmental factor only through a void in first layer 1030A.

In various aspects, layer stack 1003 includes first-exposed layer 1030Aand second-exposed layer 1030B arranged between first-exposed layer1030A and sensor patch 1030D and adjacent to first-exposed sensor patch1030A. Seals 4, 1004 are lower in susceptibility to the respectiveenvironmental factors of sensor patch 1030D, first-exposed layer 1030A,and second-exposed layer 1030B than sensor patch 1030D, first-exposedlayer 1030A, and second-exposed layer 1030B, respectively. Seals 4, 1004are arranged so that second-exposed layer 1030B is permitted to beexposed to the respective environmental factor only through a void inone or more layers 1030A farther from substrate 10 than layer 1030B. Invarious aspects, layer stack 1003 includes one or more buried layers1030C (or sensor patches) arranged between sensor patch 1030D andsecond-exposed layer 1030B, and the seal is lower in susceptibility thaneach buried layer 1030C (or sensor patch) to the respectiveenvironmental factor of that layer (here, layer 1030C).

Regardless of the number or configuration of layers or sensor patches,seal 4 and first layer 1030A (which can be a sensor patch) are arrangedto define cavity 1040 between them. Cavity 1040 is sealed off from theenvironmental factor of second layer 1030B (or sensor patch 1030D), andthe environmental factors of other layers or patches in layer stack 1003(e.g., layer 1030C, sensor patch 1030D) by seal 1004 and first layer1030A. In the example shown, seal 1004 arches over cavity 1040 andcontacts first layer 1030A to seal cavity 1040. Although not shown inthis cross-section, seal 1004 is shaped so that it, the layers in layerstack 1003, and optionally substrate 10 together enclose cavity 1040.

Second layer 1030B (or second-exposed layer 1030B, or sensor patch1030D, or another layer or patch) has flow surface 1033 (FIG. 10B)adjacent to first-exposed layer 1030A (FIG. 10A). Flow surface 1033 hasa shape, orientation, or composition that defines a flow pattern. Theflow surface can be substantially non-flat, or non-horizontal, in wholeor in part. In this example, flow surface 1033 is tilted, and the flowpattern is downhill to the left. Flow surfaces and flow patterns arediscussed below with respect to FIG. 11.

First layer 1030A is made fluid (e.g., melted or otherwise liquefiedinto a liquid, or evaporated or caused to sublimate into a gas) byexposure to the corresponding environmental factor. When first layer1030A becomes fluid, at least some of the resulting fluid travelssubstantially along flow surface 1033 into cavity 1040, following theflow pattern. For example, the fluid can travel into the cavity underthe influence of gravity. In an example, environment 320 is a gaseousenvironment, e.g., the atmosphere of the Earth. First layer 1030A canbecome fluid, resulting in a liquid. First layer 1030A can also becomefluid, resulting in a gas denser than the gas or gasses in environment320, whether due to temperature, composition, or other factors.

First layer 1030A's becoming fluid permits second layer 1030B to beexposed to the corresponding environmental factor (in general, layer1030B is exposed to environment 320 and any environmental factorstherein). In the example shown, layer 1030A is susceptible to heat. Whenlayer 1030A melts, it flows down inclined flow surface 1033 of secondlayer 1030B into cavity 1040 as mass 1031A. This permits detectingexposure to heat and subsequent exposure to a chemical. In variousaspects, the fluid of first layer 1030A travels into cavity 1040 underthe influence of surface tension or the surface wetting properties offlow surface 1033. For example, flow surface 1033 can be a surface layer1030A does not wet, and seal 1004 can be covered at least in part with amaterial that layer 1030A does wet. When layer 1030A becomes fluid, itwill pull away from flow surface 1033 and collect on seal 1004.

In various aspects, cavity 1040 is shaped so that when mass 1031A (thefluid from layer 1030A) drains into cavity 1040, it fills cavity 1040 upto or partially over (as shown) second layer 1030B. In this way, mass1030A maintains the seal, substantially preventing layers 1030C, 1030Dfrom being exposed to environment 320. When FIGS. 10A and 10B are viewedat the same scale (e.g., by magnifying so that seal 1004 is the samesize on both figures), layer 1030A and mass 1031A have substantially thesame area. Those equal areas are a graphical representation of the factthat, in various aspects, if mass 1031A is at the same temperature aslayer 1030A, mass 1031A will have the same volume as layer 1030A (invarious aspects, e.g., if mass 1031A cools below its meltingtemperature). In other aspects, layer 1030A undergoes a non-reversiblevolume change when it becomes fluid.

In various aspects, seal 1004 is shaped or oriented to reduceenvironmental ingress while layer 1030A becomes fluid. In an example,seal 1004 protrudes into layer 1030A, leaving only a narrow gap betweenseal 1004 and second layer 1030B. This is shown by the dotted outline atthe end of seal 1004 in FIG. 10A. As layer 1030A becomes fluid, theforce of gravity pulls fluid layer 1030A through the gap, displacing airthat bubbles out through the gap. In this way, either the gap issubstantially environment-impermeable, or the gap is under positivepressure out of cavity 1040, while fluid layer 1030A drains into cavity1040. This reduces the extent to which any environmental factors fromenvironment 320 can enter cavity 1040 until mass 1030A has sealed layers1030B, 1030C, 1030D.

In various aspects, cavity 1040 includes a desiccant, getter, or othermaterial that absorbs, adsorbs, or otherwise retains mass 1031A. Invarious aspects, the sensing system includes fixed elements notsusceptible to the corresponding environmental factors of layers 1030A,1030B, 1030C, 1030D, e.g., vanes or chutes, that direct, collect, ortransport fluid from layer 1030A.

In various aspects, first layer 1030A and second layer 1030B aresusceptible to heat (e.g., have respective melting points). Layers1030A, 1030B have respective selected thermal conductances, which dependon the geometry and composition of the layers 1030A, 1030B,respectively. The thermal conductance of layer 1030A is greater than athermal conductance of seal 1004. In this way, heat energy primarilyreaches layer 1030B only through layer 1030A. In these aspects, layer1030A is considered a void with respect to layer 1030B and seal 1004once layer 1030A becomes fluid at least in part, or reaches its meltingor boiling temperature (at least in part), or once the rate of heattransfer between layer 1030A and layer 1030B reaches a selected level,or once layer 1030B reaches a selected temperature. The level can be,e.g., when layer 1030B is increasing 1° C. per minute. The temperaturecan be, e.g., when layer 1030B has a temperature midway between aninitial temperature and a temperature of environment 320. In variousaspects, layer 1030A is formed from a low-melting-temperature metal suchas Wood's metal, Field's metal, Cerrosafe, Rose's metal, or othercompounds having melting points below 100° C. Various bismuth-tin alloyscan be used for this purpose. Higher-melting-temperature metals, e.g.,tin (which melts at about 232° C.), can also be used.

In various aspects, first layer 1030A is susceptible to heat (e.g., hasa specific melting point). Layer 1030B is not susceptible to heat ortemperature, so layer 1030A is not considered a void with respect tolayer 1030B and seal 1004. When layer 1030A becomes fluid and at least apart moves or otherwise exposes a portion of layer 1030B, the volumeformerly occupied by material of layer 1030A is a void. Layer 1030A canbe formed from various metals, including Bi—Sn alloys, as describedabove.

In various aspects, layer 1030A is a first-exposed sensor patch. Patch1030A consists of an electrically-conductive material and zero or moreinclusions (e.g., air bubbles, dust particles, or other non-conductiveor less-conductive particles) that together do not reduce theconductivity of the electrically-conductive material by more thanfifteen percent. For example, layer 1030A can be a conductive metal.When the metal melts, it flows into cavity 1040. This exposes layer1030B to environment 320 and also opens a connection between twootherwise separate electrodes formerly connected by layer 1030A.

In various aspects not shown here, first layer 1030A can become a gas onexposure to the corresponding environmental factor, and that gas candissipate into or through environment 320. This exposes second layer1030B to environmental factors in environment 320 but does not maintaina seal on layers below second layer 1030B. In various aspects, as shownin FIG. 1A, seal 4 is in contact with layers 2A, 2B, 2C around theirperimeters, leaving no cavities. When layer 2C evaporates, layer 2B ispermitted to be exposed to environment 320, and seal 4 and layer 2Btogether protect layer 2A from exposure to environment 320 until layer2B burns through.

Referring back to FIG. 7, a layer stack (or patch stack) and sealarrangement such as shown in FIGS. 10A-10B can also be used with sensorpatches 30. In various aspects, one or more layer(s) (or patch(es);layer(s) can be conductive or not) are disposed over a selected one ofthe sensor patches 30 in a selected order, as described above withrespect to FIG. 1. Each layer is susceptible to a respectiveenvironmental factor, so that the selected one of the sensor patches 30changes conductance in response to exposure of the layer stack to therespective environmental factors of the one or more layer(s) in theselected order and subsequent exposure of the sensor patch 30 to thecorresponding environmental factor. Seal 1004 (FIG. 10A) and relatedcomponents can also be used as described above. Each buried layer orpatch can be permitted to be exposed to the respective environmentalfactor only through respective void(s) in the one or more layer(s)farther from the substrate than that buried layer.

Referring back to FIG. 8, a layer stack (patch stack) and optionallyseal 1004 (FIG. 10A) as described above can also be disposed over aselected one of the sensor patches 30A, 30B, 30C, 30D. Layers 30E, 30F,and seal 4 can be as discussed above with respect to FIGS. 10A-10B(layers 1030A, 1030B, 1030C; seal 1004). In an example, sensor patch 30Dhas disposed over it layer 30E (layer 30F is not used). Sensor patch 30Dincludes a sensor-patch layer (not shown) susceptible to theenvironmental factor of sensor patch 30D. The sensor-patch layer has aflow surface adjacent to layer 30E so that when layer 30E is made fluid,the fluid will flow according to a flow pattern along the flow surfaceof the sensor-patch layer.

FIG. 11 is an isometric view of a flow surface according to variousaspects. Layer 1030 has flow surface 1033. In this example, flow surface1033 descends from peak 1130 in segments 1133L, 1133C, 1133R (left,center, right), outlined by solid lines. Dotted lines show theprojection of the solid lines on the horizontal. Direction G of gravityis straight down in this example. In various aspects, direction G is thedirection of the sum of forces acting on the material on top of layer1030 immediately before that material begins to liquefy.

As a result, when material on top of layer 1030 liquefies, it will flowdown segments 1133L, 1133C, 1133R according to flow pattern 1111 (dashedarrows). Gravity pulls fluid disposed over each segment 1133L, 1133C,1133R along that segment and away from peak 1130. Flow pattern 1111indicates the directions and velocities fluid is likely to flow alongflow surface 1033. Fluid may flow in other directions due to localizedor unanticipated forces acting on the fluid, but will generally followthe flow pattern. In general, the fluid pattern at any point is thevector sum of the forces acting on the fluid at that point.

FIG. 12 is a block diagram of an RFID system according to variousaspects. Base station 710 communicates with three RF tags 722, 724, 726,which can be active or passive in any combination, via a wirelessnetwork across an air interface 712. FIG. 12 shows three tags, but anynumber can be used. Base station 710 includes reader 714, reader'santenna 716 and RF station 742. RF station 742 includes an RFtransmitter and an RF receiver (not shown) to transmit and receive RFsignals via reader's antenna 716 to or from RF tags 722, 724, 726. Tags722, 724, 726 transmit and receive via respective antennas 730, 744,748.

Reader 714 includes memory unit 718 and logic unit 720. Memory unit 718can store application data and identification information (e.g., tagidentification numbers) or SG TINs of RF tags in range 752 (RF signalrange) of reader 714. Logic unit 720 can be a microprocessor, FPGA, PAL,PLA, or PLD. Logic unit 720 can control which commands that are sentfrom reader 714 to the tags in range 752, control sending and receivingof RF signals via RF station 742 and reader's antenna 716, or determineif a contention has occurred.

Reader 714 can continuously or selectively produce an RF signal whenactive. The RF signal power transmitted and the geometry of reader'santenna 716 define the shape, size, and orientation of range 752. Reader714 can use more than one antenna to extend or shape range 752.

RFID standards exist for different frequency bands, e.g., 125 kHz (LF,inductive or magnetic-field coupling in the near field), 13.56 MHz (HF,inductive coupling), 433 MHz, 860-960 MHz (UHF, e.g., 915 MHz, RFcoupling beyond the near field), or 2.4 GHz. Tags can use inductive,capacitive, or RF coupling (e.g., backscatter) to communicate withreaders.

Radio frequency identification systems are typically categorized aseither “active” or “passive.” In an active RFID system, tags are poweredby an internal battery, and data written into active tags can berewritten and modified. In a passive RFID system, tags operate withoutan internal power source and are typically programmed with a unique setof data that cannot be modified. A typical passive RFID system includesa reader and a plurality of passive tags. The tags respond with storedinformation to coded RF signals that are typically sent from the reader.Further details of RFID systems are given in commonly-assigned U.S. Pat.No. 7,969,286 to Adelbert, and in U.S. Pat. No. 6,725,014 to Voegele,both of which are incorporated herein by reference.

In a commercial or industrial setting, tags can be used to identifycontainers of products used in various processes. A container with a tagaffixed thereto is referred to herein as a “tagged container.” Tags oncontainers can carry information about the type of products in thosecontainers and the source of those products. A tag on a container cancarry the SGTIN(s) for item(s) in the container.

FIG. 13 is a block diagram of a passive RFID tag (e.g., tags 722, 724,726 shown in FIG. 12) according to various aspects. The tag can be alow-power integrated circuit, and can employ a “coil-on-chip” antennafor receiving power and data. The RFID tag includes antenna 854 (ormultiple antennas), power converter 856, demodulator 858, modulator 860,clock/data recovery circuit 862, control unit 864, and output logic 880.Antenna 854 can be an omnidirectional antenna impedance-matched to thetransmission frequency of reader 714 (FIG. 12). The RFID tag can includea support, for example, a piece of polyimide (e.g., KAPTON) withpressure-sensitive adhesive thereon for affixing to packages. The tagcan also include a memory (often RAM in active tags or ROM in passivetags) to record digital data, e.g., an SGTIN.

Reader 714 (FIG. 12) charges the tag by transmitting a charging signal,e.g., a 915 MHz sine wave. When the tag receives the charging signal,power converter 856 stores at least some of the energy received byantenna 854 in a capacitor, or otherwise stores energy to power the tagduring operation.

After charging, reader 714 transmits an instruction signal by modulatingonto the carrier signal data for the instruction signal, e.g., tocommand the tag to reply with a stored SGTIN. Demodulator 858 receivesthe modulated carrier bearing those instruction signals. Control unit864 receives instructions from demodulator 858 via clock/data recoverycircuit 862, which can derive a clock signal from the received carrier.Control unit 864 determines data to be transmitted to reader 714 andprovides it to output logic 880. For example, control unit 864 canretrieve information from a laser-programmable or fusible-link registeron the tag. Output logic 880 shifts out the data to be transmitted viamodulator 860 to antenna 854. The tag can also include a cryptographicmodule (not shown). The cryptographic module can calculate secure hashes(e.g., SHA-1) of data or encrypt or decrypt data using public- orprivate-key encryption. The cryptographic module can also perform thetag side of a Diffie-Hellman or other key exchange.

Signals with various functions can be transmitted; some examples aregiven in this paragraph. Read signals cause the tag to respond withstored data, e.g., an SGTIN. Command signals cause the tag to perform aspecified function (e.g., kill). Authorization signals carry informationused to establish that the reader and tag are permitted to communicatewith each other.

Passive tags typically transmit data by backscatter modulation to senddata to the reader. This is similar to a radar system. Reader 714continuously produces the RF carrier sine wave. When a tag enters thereader's RF range 752 (FIG. 12; also referred to as a “field of view”)and receives, through its antenna from the carrier signal, sufficientenergy to operate, output logic 880 receives data, as discussed above,which is to be backscattered.

Modulator 860 then changes the load impedance seen by the tag's antennain a time sequence corresponding to the data from output logic 880.Impedance mismatches between the tag antenna and its load (the tagcircuitry) cause reflections, which result in momentary fluctuations inthe amplitude or phase of the carrier wave bouncing back to reader 714.Reader 714 senses occurrences and timing of these fluctuations anddecodes them to receive the data clocked out by the tag. In variousaspects, modulator 860 includes an output transistor (not shown) thatshort-circuits the antenna in the time sequence (e.g., short-circuitedfor a 1 bit, not short-circuited for a 0 bit), or opens or closes thecircuit from the antenna to the on-tag load in the time sequence. Inanother aspect, modulator 860 connects and disconnects a load capacitoracross the antenna in the time sequence. Further details of passive tagsand backscatter modulation are provided in U.S. Pat. No. 7,965,189 toShanks et al. and in “Remotely Powered Addressable UHF RFID IntegratedSystem” by Curty et al., IEEE Journal of Solid-State Circuits, vol. 40,no. 11, November 2005, both of which are incorporated herein byreference. As used herein, both backscatter modulation and activetransmissions are considered to be transmissions from the RFID tag. Inactive transmissions, the RFID tag produces and modulates a transmissioncarrier signal at the same wavelength or at a different wavelength fromthe read signals from the reader.

Voltage values associated with a ground signal or a voltage signal canbe chosen to suit the needs of the integrated circuits, power supplies,and other electronic elements. The present invention is not limited toany particular voltage ranges or differences, either positive ornegative, used to provide power, excitation signals, or detectionsignals. For example, a negative voltage V− can be used with a groundsignal as well as a positive voltage V+.

The invention is inclusive of combinations of the aspects describedherein. References to “a particular aspect” and the like refer tofeatures that are present in at least one aspect of the invention.Separate references to “an aspect” or “particular aspects” or the likedo not necessarily refer to the same aspect or aspects; however, suchaspects are not mutually exclusive, unless so indicated or as arereadily apparent to one of skill in the art. The use of singular orplural in referring to the “method” or “methods” and the like is notlimiting. The word “or” is used in this disclosure in a non-exclusivesense, unless otherwise explicitly noted.

The invention has been described in detail with particular reference tocertain preferred aspects thereof, but it will be understood thatvariations, combinations, and modifications can be effected by a personof ordinary skill in the art within the spirit and scope of theinvention.

PARTS LIST

-   2A, 2B, 2C layer-   3 layer stack-   4, 4A seal-   5 electronic sensing system-   9 detection region-   10 substrate-   11 planarization layer-   12 output pad-   13 seal-   14 input pad-   16 code circuit-   20 transceiver-   21 transceiver substrate-   22 excitation circuit-   24 detection circuit-   26 interface-   28 antenna-   30, 30A, 30B, 30C, 30D, 30E, 30F sensor patch-   42 memory-   56 electrical connector-   57 electrode-   74 security circuit-   80 downlink signal-   82 uplink signal-   88 controller-   89 reader-   302C electrically-conductive layer-   309Z electrically-insulating layer-   310 sensor patch-   312C electrically-conductive layer-   319Z electrically-insulating layer-   320 environment-   403W window-   403Z electrically-insulating layer-   405C conductor-   503 patch stack-   512, 514 conductor-   530A, 530B, 530C sensor patch-   710 base station-   712 air interface-   714 reader-   716 reader's antenna-   718 memory unit-   720 logic unit-   722, 724, 726 RFID tag-   730, 744, 748 antenna-   742 RF station-   752 range-   803 patch stack-   854 antenna-   856 power converter-   858 demodulator-   860 modulator-   862 clock/data recovery circuit-   864 control unit-   880 output logic-   905 dispose sensor patches step-   910 expose code circuit step-   919 expose multiple circuits step-   920 check code circuit step-   925 compare with criterion step-   929 check multiple circuits step-   930 store electrical signal step-   935 transmit signal step-   939 store signals step-   940 interval elapsed? decision step-   1003 layer stack-   1004 seal-   1030 layer-   1030A first-exposed layer-   1030B second-exposed layer-   1030C, 1030D layer-   1031A mass-   1033 flow surface-   1040 cavity-   1111 flow pattern-   1130 peak-   1133L, 1133C, 1133R segment-   G direction of gravity

The invention claimed is:
 1. A method of sensing exposure to one or moreof a plurality of environmental factors, comprising steps of: anexposing step of exposing a code circuit to at least some of theenvironmental factors, the code circuit disposed over a substrate andincluding a plurality of sensor patches, each sensor patch having arespective electrical state that changes with exposure to one of theenvironmental factors, so that the code circuit has an electrical state;a checking step of passing an electrical excitation signal through thecode circuit, and detecting a corresponding received electrical signal,using a transceiver formed on a transceiver substrate separate from anddisposed over the substrate, wherein the transceiver includes acontroller and the received electrical signal depends on the excitationsignal and the electrical state of the code circuit; a storing step ofusing the controller, automatically storing the received electricalsignal or a representation thereof in a memory; and a repeating step ofusing the controller, automatically repeating the checking and storingsteps after one or more selected time intervals; and wherein: theexposing step includes contemporaneously exposing a plurality of codecircuits to the at least some of the environmental factors, each codecircuit disposed over the substrate and including a respective pluralityof electrically-connected sensor patches, each sensor patch having anelectrical state that changes with exposure to a corresponding one ofthe one or more environmental factors, so that each code circuit has arespective electrical state; the checking step includes passing arespective electrical excitation signal through each code circuit anddetecting a respective received electrical signal; and the storing stepincludes, using the controller, automatically storing the respectivereceived electrical signals or respective representations thereof in thememory.
 2. The method according to claim 1, further including thecontroller receiving a downlink signal and, in response, transmitting anuplink signal representing the stored received electrical signal orrepresentation thereof.
 3. The method according to claim 1, wherein thechecking step further includes the controller automatically comparingthe received electrical signal with a selected criterion and, if thesignal corresponds to the criterion, activating an actuator.
 4. Themethod according to claim 3, wherein the actuator is adapted to dispensea drug when activated.
 5. The method according to claim 1, wherein eachof the sensor patches further includes a respectiveelectrically-conductive layer susceptible to the corresponding one ofthe environmental factors, so that each of the sensor patches changeselectrical state when exposed to the corresponding one of theenvironmental factors.
 6. The method according to claim 1, wherein aselected one of the sensor patches further includes anelectrically-conductive layer susceptible to the correspondingenvironmental factor, so that the selected sensor patch changeselectrical state when exposed to the corresponding one of theenvironmental factors.
 7. The method according to claim 1, wherein oneof the sensor patches further includes an electrically-insulating layerand a conductor arranged on a side of the electrically-insulating layercloser to the substrate, the electrically-insulating layer and theconductor susceptible to the corresponding environmental factor.
 8. Themethod according to claim 1, wherein one of the sensor patches furtherincludes an electrically-insulating layer and a conductor arranged on aside of the electrically-insulating layer closer to the substrate, theelectrically-insulating layer susceptible to the correspondingenvironmental factor and the conductor susceptible to a respectiveenvironmental factor different from the corresponding environmentalfactor of the electrically-insulating layer.
 9. The method according toclaim 1, wherein a first one of the code circuits includes respectivesensor patches that are susceptible to a first subset of the pluralityof environmental factors and a second one of the code circuits includesrespective sensor patches that are susceptible to a second subset of theplurality of environmental factors different from the first subset. 10.The method according to claim 1, further including, before the exposingstep, disposing the sensor patches of the code circuit over thesubstrate by depositing respective conductors and printing respectivesusceptible layers over the conductors, each susceptible layersusceptible to a corresponding one of the one or more environmentalfactors.
 11. The method according to claim 1, wherein the sensor patchesare arranged in a patch stack including a first-exposed one of thesensor patches and one or more buried ones of the sensor patchesarranged between the first-exposed one of the sensor patches and thesubstrate, and the code circuit includes a seal lower in susceptibilityto each of the respective environmental factors than the respectivesensor patches in the patch stack, the seal arranged so that each of theburied sensor patches is permitted to be exposed to the respectiveenvironmental factor only through a void in one or more of the sensorpatches farther from the substrate than that buried sensor patch. 12.The method according to claim 11, wherein the sensor patches areelectrically connected in parallel.
 13. The method according to claim11, wherein the first-exposed sensor patch is susceptible to heat andhas a selected thermal conductance greater than a thermal conductance ofthe seal.
 14. The method according to claim 13, wherein thefirst-exposed sensor patch consists of an electrically-conductivematerial and zero or more inclusions that together do not reduce theconductivity of the electrically-conductive material by more thanfifteen percent.
 15. The method according to claim 1, wherein the sensorpatches are electrically connected in series.
 16. A method of sensingexposure to one or more of a plurality of environmental factors,comprising steps of: an exposing step of exposing a code circuit to atleast some of the environmental factors, the code circuit disposed overa substrate and including a plurality of sensor patches, each sensorpatch having a respective electrical state that changes with exposure toone of the environmental factors, so that the code circuit has anelectrical state; a checking step of passing an electrical excitationsignal through the code circuit, and detecting a corresponding receivedelectrical signal, using a transceiver formed on a transceiver substrateseparate from and disposed over the substrate, wherein the transceiverincludes a controller and the received electrical signal depends on theexcitation signal and the electrical state of the code circuit; astoring step of using the controller, automatically storing the receivedelectrical signal or a representation thereof in a memory; a repeatingstep of using the controller, automatically repeating the checking andstoring steps after one or more selected time intervals; wherein thechecking step further includes the controller automatically comparingthe received electrical signal with a selected criterion and, if thesignal corresponds to the criterion, activating an actuator adapted todispense a drug when activated.
 17. The method according to claim 16,wherein the actuator dispenses the drug into the gastrointestinal tractor circulatory system of a human or animal.
 18. A method of sensingexposure to one or more of a plurality of environmental factors,comprising steps of: an exposing step of exposing a code circuit to atleast some of the environmental factors, the code circuit disposed overa substrate and including a plurality of sensor patches, each sensorpatch having a respective electrical state that changes with exposure toone of the environmental factors, so that the code circuit has anelectrical state; a checking step of passing an electrical excitationsignal through the code circuit, and detecting a corresponding receivedelectrical signal, using a transceiver formed on a transceiver substrateseparate from and disposed over the substrate, wherein the transceiverincludes a controller and the received electrical signal depends on theexcitation signal and the electrical state of the code circuit; astoring step of using the controller, automatically storing the receivedelectrical signal or a representation thereof in a memory; a repeatingstep of using the controller, automatically repeating the checking andstoring steps after one or more selected time intervals; and wherein:the sensor patches are arranged in a patch stack including afirst-exposed one of the sensor patches and one or more buried ones ofthe sensor patches arranged between the first-exposed one of the sensorpatches and the substrate, and the code circuit includes a seal lower insusceptibility to each of the respective environmental factors than therespective sensor patches in the patch stack, the seal arranged so thateach of the buried sensor patches is permitted to be exposed to therespective environmental factor only through a void in one or more ofthe sensor patches farther from the substrate than that buried sensorpatch; the one or more buried ones of the sensor patches include asecond-exposed sensor patch adjacent to the first-exposed sensor patch;the seal and patch stack are arranged to define a cavity between them,the cavity sealed off from the environmental factors of the plurality ofsensor patches by the seal and the first-exposed sensor patch; the patchstack is arranged so that the second-exposed layer has a flow surfaceadjacent to the first-exposed layer, the flow surface having a shape,orientation, or composition that defines a flow pattern; and thefirst-exposed sensor patch is made fluid by exposure to thecorresponding environmental factor, so that when the first-exposedsensor patch becomes fluid, at least some of the resulting fluid travelssubstantially according to the flow pattern into the cavity to permitthe second-exposed sensor patch to be exposed to the correspondingenvironmental factor.